Longevity of duct tape in residential air distribution systems: 1-D, 2-D, and 3-D joints

The aging tests conducted so far showed that duct tape tends to degrade in its performance as the joint it is applied to requires a geometrical description of a higher number of space dimensions (1-D, 2-D, 3-D). One-dimensional joints are the easiest to seal with duct tape, and thus the least to experience failure. Two-dimensional joints, such as the flexible duct core-to-collar joints tested in this study, are less likely to fail than three-dimensional collar-to-plenum joints, as the shrinkage could have a positive effect in tightening the joint. Three-dimensional joints are the toughest to seal and the most likely to experience failure. The 2-D flexible duct core-to-collar joints passed the six-month period of the aging test in terms of leakage, but with the exception of the foil-butyl tape, showed degradation in terms hardening, brittleness, partial peeling, shrinkage, wrinkling, delamination of the tape layers, flaking, cracking, bubbling, oozing and discoloration. The baking test results showed that the failure in the duct tape joints could be attributed to the type of combination of the duct tape and the material it is applied to, as the duct tape behaves differently with different substrates. Overall, the foil-butyl tape (Tape 4) had the best results, while the film tape (Tape 3) showed the most deterioration. The conventional duct tapes tested (Tape 1 and Tape 2) were between these two extremes, with Tape 2 performing better than Tape 1. Lastly, we found that plastic straps became discolored and brittle during the tests, and a couple of straps broke completely. Therefore, we recommend that clamping the duct-taped flexible core-to-collar joints should be done with metallic adjustable straps